Cable harness assembly for bicycle

ABSTRACT

A cable harness assembly is provided on a bicycle for guiding a disk brake control hose in accompaniment of the cable stoppers brazed on a bicycle frame. The cable harness assembly basically has a hose hanger, a hanger stopper, a stopper bushing and a hanger fixing bolt. The hose hanger includes a body portion of a first outer diameter or width and formed with a first axial bore therethrough, and a cable portion extending from the body portion. The hanger stopper of a second outer diameter or width is smaller than the first outer diameter or width. The hanger stopper is formed with a halting piece extending from the hanger stopper and a second axial bore therethrough. The stopper bushing is sandwiched between the hose hanger and the hanger stopper and formed with a third axial bore therethrough. The stopper bushing is made of a radially expandable material and has a third outer diameter or width being normally approximate to the second outer diameter or width. The hanger fixing bolt is used for assembling the hose hanger, the hanger stopper, and the stopper bushing together by being fastened through the first axial bore of the hose hanger, the third axial bore of the stopper bushing, and the second axial bore of the hanger stopper. The third outer diameter or width of the stopper bushing increases when the fixing bolt is fastened to the second axial bore of the hanger stopper forcing the hose hanger and the hanger stopper to press against the stopper bushing. A further embodiment including a hose hanger and a stopper bushing is disclosed where the stopper bushing will rotate and skew with respect to the hose hanger while performing the fastening operation.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of copending U.S. patentapplication Ser. No. 09/488,711, filed Jan. 21, 2000.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention generally relates to a cable harness assembly for abicycle. More specifically, the present invention relates to a cableharness assembly for guiding a disk brake control hose, a control cableor the like in accompaniment with a conventional cable stopper brazed ona bicycle frame.

2. Background Information

An arrangement of a generic cable harness is described in the ROC(Taiwan) Patent Publication No. 361417, such as that in FIG. 10. Thistype of cable harness A includes a cable gripper 33, a connector 30 anda connecting screw 31. The cable harness A is mounted to a bicycle bybeing mounted to a conventional cable stopper 11 brazed on the bicycleframe.

However, in such a type of cable harness A, the connector screw 31 mustbe detached from the connector 30 and then removed from the cablegripper 33 prior to being mounted to a cable stopper 11 of the bicycleframe. This arrangement is thus tedious to use and may easily result inlosing small parts after dismantling.

The necessity arises of mounting a cable harness to the cable stopperwithout having to dismantle the cable harness in order to carry outmounting operations.

In view of the above, there exists a need for a cable harness assemblywhich overcomes the above mentioned problems in the prior art. Thisinvention addresses this need in the prior art as well as other needs,which will become apparent to those skilled in the art from thisdisclosure.

SUMMARY OF THE INVENTION

One object of the present invention is to provide a cable harnessassembly that is easy to install.

More specifically, an object of the invention to design an arrangementfor holding hoses, cables, or hydraulic lines in such a way that easymounting is possible without the necessity to dismantle the cableharness assembly. As a result, losing of small parts can also beprevented and mounting can be easily accomplished without involvingextraneous work.

To achieve the intended object, this invention discloses a cable harnessassembly comprising a hose hanger, a hanger stopper, a stopper bushingand a hanger fixing bolt, wherein the stopper bushing expands when thefixing bolt is fastened to the hanger stopper forcing the hose hangerand the hanger stopper to press against the stopper bushing.

A further embodiment including a hose hanger and a stopper bushing isdisclosed where the stopper bushing will rotate and skew with respect tothe hose hanger while performing the fastening operation.

These and other objects, features, aspects and advantages of the presentinvention will become apparent to those skilled in the art from thefollowing detailed description, which, taken in conjunction with theannexed drawings, discloses a preferred embodiment of the presentinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the attached drawings which form a part of thisoriginal disclosure:

FIG. 1 is an exploded view illustrating the cable harness assembly inaccordance with one embodiment of this invention;

FIG. 2 is a cross-sectional view illustrating the cable harness assemblyof FIG. 1 before being mounted to a cable stopper brazed on a bicycleframe;

FIG. 3 is a cross-sectional view illustrating the cable harness assemblyof FIG. 1 after being mounted to a cable stopper brazed on a bicycleframe;

FIG. 4 is an exploded view illustrating a second embodiment of a cableharness assembly of this invention;

FIG. 5 is a cross-sectional view illustrating the cable harness assemblyof FIG. 4 before being mounted to a cable stopper brazed on a bicycleframe;

FIG. 6 is an exploded view illustrating a third embodiment of a cableharness assembly of this invention;

FIG. 7 is a cross-sectional view illustrating the cable harness assemblyof FIG. 6 before being mounted to a cable stopper brazed on a bicycleframe;

FIG. 8 is a cross-sectional view illustrating a fourth embodiment of acable harness assembly of this invention, in which a hose hanger has aone-piece structure.

FIG. 9 illustrates a hose or a hydraulic line being guided through acable harness assembly of this invention;

FIG. 10 illustrates a conventional prior art cable harness that isattached to a cable stopper brazed on a bicycle frame; and

FIG. 11 is a cross-sectional view illustrating a fourth embodiment of acable harness assembly of this invention, in which a hose hanger has atwo-piece structure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in FIG. 1, a cable harness assembly 100 a is illustrated inaccordance with one embodiment of the present invention. The cableharness assembly 100 a basically comprises a hose hanger 1 a, a hangerstopper 2 a, a stopper bushing 3 a and a hanger fixing bolt 4. The hosehanger 1 a includes a body portion 12, a cable portion 16, and oppositeends 15 and 17. The body portion 12 has a first outer diameter or widththat has a first axial bore 14 extending between opposite ends 15 and17. The cable portion 16 extends outwardly from the body portion 12 forreceiving a control cable or hose.

To enhance the flexibility of the hose hanger 1 a, the body portion 12and the cable portion 16 of the hose hanger 1 a can be joined by a neckportion 18. The hose hanger 1 a is preferably integrally formed as aone-piece, unitary member by injection molding. The cable portion 16 ofthe hose hanger 1 a is formed with a longitudinal opening or slot 162,preferably be configured to have a C-shaped cross-section. The C-shapedconfiguration of slot 162 has an inner diameter or width that isproximate to the outer diameter or width of a hose or hydraulic line 60,to be held in the cable portion 16 as seen in FIG. 3.

The hanger stopper 2 a has opposite ends 21 and 23 and a second outerdiameter or width, that is preferably slightly smaller than the firstouter diameter or width of the body portion 12. The hanger stopper 2 ais formed with a second axial bore 22 extending between opposite ends 21and 23. A halting piece 24 further extends from the hanger stopper 2 a,preferably in an outwardly radial direction. The halting piece 24 has arectangular configuration. The function of the halting piece 24 will bedescribed later.

The stopper bushing 3 a has opposite ends 37 and 38. The stopper bushing3 a is sandwiched between the hose hanger 1 a and the hanger stopper 2a, and formed with a third axial bore 32 therethrough. The stopperbushing 3 a is made of a radially expandable material, that has a thirdouter diameter or width being normally approximate to the second outerdiameter or width of the hanger stopper 2 a. In the embodiment shown inFIGS. 1-3, the radially expandable material for making the stopperbushing 3 a is a resilient material, such as rubber.

To assemble the hose hanger 1 a, the hanger stopper 2 a and the stopperbushing 3 a together, the hanger fixing bolt 4 is inserted through thefirst axial bore 14 of the hose hanger 1 a, the third axial bore 32 ofthe stopper bushing 3 a and the second axial bore 22 of the hangerstopper 2 a. Prior to mounting of the cable harness assembly 100 a to abicycle frame, a tip end of the hanger fixing bolt 4 is inserted andthreaded into the second axial bore 22 of the hanger stopper 2 a by ashort distance sufficient to hold the hose hanger 1 a, the stopperbushing 3 a and the hanger stopper 2 a together, but without providingexternal forces on the stopper bushing 3 a, as shown in FIG. 2.

In use, the cable harness assembly 100 a is inserted into a cablestopper 42 that is formed with an inner wall 44 and is conventionallybrazed to a bicycle frame 40. The lateral end 15 of the hose hanger 1 anext to the stopper bushing 3 a then urges against a lateral end of thecable stopper 42. The halting piece 24 extending from the hanger stopper2 a is inserted through a slit (not shown) of the cable stopper 42 tohalt the hanger stopper 2 a from further rotation driven by the hangerfixing bolt 4. A tool (not shown) is then implemented to drive thehanger fixing bolt 4 such that the fixing bolt 4 is fastened to thesecond axial bore 22 of the hanger stopper 2 a. The second axial bore 22of the hanger stopper 2 a may be formed with threads (not shown) thereinso as to facilitate the fastening operation. The fixing bolt 4 may alsobe fastened to the second axial bore 22 in a self-tapping manner so asto reduce manufacturing cost of the hanger stopper 2 a.

In the embodiments as shown in FIGS. 1-3, the third diameter or width ofthe stopper bushing 3 a will expand in one way or another as a result ofthe fastening operation of the hanger fixing bolt 4, so as to attain thedesired mounting effect to the bicycle frame 40. Afterwards, a hose orhydraulic line 60 can be inserted into the cable portion 16 of the hosehanger 1 a by being pressed through the longitudinal opening 162 so asto be secured to the bicycle frame 40, as shown in FIG. 9.

In a further embodiment shown in FIGS. 4 and 5, the lateral ends 21 ofthe hanger stopper 2 b next to the stopper bushing 3 b tapers radiallyinwards. The radially expandable material for making the stopper bushing3 b is a deformable, rigid material, such as metal or plastic. Thestopper bushing 3 b is further formed with at least one blind slit 34along a longitudinal direction thereof. The cooperation between thetapering lateral end 21 and the slits 34 will be described later.

Accordingly, in the embodiment as shown in FIGS. 1-3, the fasteningoperation will force the hanger stopper 2 a to move towards the stopperbushing 3 a so as to press against the stopper bushing 3 a, such thatthe third outer diameter or width of the stopper bushing 3 a increasesdue to radial deformation to a point to urge against the inner wall 44of the cable stopper 42 so as to secure the cable harness 100 a to thebicycle frame 40 due to radial expansion of the stopper bushing 3 a.

The second embodiment is assembled in substantially the same manner asthe first embodiment. The hose hanger 1 b, the hanger stopper 2 b andthe stopper bushing 3 b are coupled together by inserting the hangerfixing bolt 4 through the first axial bore 14 of the hose hanger 1 b,the third axial bore 32 of the stopper bushing 3 b and the second axialbore 22 of the hanger stopper 2 b. Prior to mounting of the cableharness assembly 100 b to a bicycle frame, a tip end of the hangerfixing bolt 4 is inserted and threaded into the second axial bore 22 ofthe hanger stopper 2 b by a distance sufficient to hold the hose hanger1 b, the stopper bushing 3 b and the hanger stopper 2 b together, butwithout providing external forces on the stopper bushing 3 b, as shownin FIG. 5.

In use, the cable harness assembly 100 b is inserted into a cablestopper 42 that is formed with an inner wall 44 and is conventionallybrazed to a bicycle frame 40. The lateral end 15 of the hose hanger 1 bnext to the stopper bushing 3 b then urges against a lateral end of thecable stopper 42. The halting piece 24 extending from the hanger stopper2 b is inserted through a slit (not shown) of the cable stopper 42 tohalt the hanger stopper 2 b from further rotation driven by the hangerfixing bolt 4. A tool (not shown) is then implemented to drive thehanger fixing bolt 4 such that the fixing bolt 4 is fastened to thesecond axial bore 22 of the hanger stopper 2 b. The second axial bore 22of the hanger stopper 2 b may be formed with threads (not shown) thereinso as to facilitate the fastening operation. The fixing bolt 4 may alsobe fastened to the second axial bore 22 in a self-tapping manner so asto reduce manufacturing cost of the hanger stopper 2 b.

In the embodiment as shown in FIGS. 4 and 5, the fastening operationwill force the hanger stopper 2 b to move towards the stopper bushing 3b subjecting the tapering lateral end 21 of the hanger stopper 2 b totuck into the third axial bore 32 of the stopper bushing 3 b and causingthe stopper bushing 3 b to expand and flare open due to the slits 34provided on the stopper bushing 3 b, so as to secure the cable harnessassembly 100 b to the bicycle frame 40 due to radial expansion of thestopper bushing 3 b at the flared portion.

In the embodiments as shown in FIGS. 4 and 5, the third diameter orwidth of the stopper bushing 3 b will expand in one way or another as aresult of the fastening operation of the hanger fixing bolt 4, so as toattain the desired mounting effect to the bicycle frame 40. Afterwards,a hose or hydraulic line 60 can be inserted into the cable portion 16 ofthe hose hanger 1 b by being pressed through the longitudinal opening162 to be secured to the bicycle frame 40, as shown in FIG. 9.

In still a further embodiment shown in FIGS. 6 and 7, a portion of thelateral end 15 of the hose hanger 1 c next to the stopper bushing 3 calso tapers radially inwards, preferably from a radial location that isapproximate to the second outer diameter or width of the hanger stopper2 c. In this particular embodiment, the stopper bushing 3 c is aC-shaped member 36, preferably made of metal or plastic, with a thirdaxial bore 32 as shown. The cooperation between the tapering lateralends 21, the portion of the lateral end 15 and the C-shaped member 36will be described later.

The third embodiment is assembled in substantially the same manner asthe first embodiment. To assemble the hose hanger 1 c, the hangerstopper or and the stopper bushing 3 c together, the hanger fixing bolt4 is inserted through the first axial bore 14 of the hose hanger 1 c,the third axial bore 32 of the stopper bushing 3 c, and the second axialbore 22 of the hanger stopper 2 c. Prior to mounting of the cableharness assembly 100 c to a bicycle frame, a tip end of the hangerfixing bolt 4 is inserted and threaded into the second axial bore 22 ofthe hanger stopper 2 c by a short distance sufficient enough to hold thehose hanger 1 c, the stopper bushing 3 c, and the hanger stopper 2 ctogether, but without providing external forces on the stopper bushing 3c, such as those shown in FIG. 7.

In use, the cable harness assembly 100 c is inserted into a cablestopper 42 that is formed with an inner wall 44 and is conventionallybrazed to a bicycle frame 40. The lateral end 15 of the hose hanger 1 cnext to the stopper bushing 3 c then urges against a lateral end of thecable stopper 42. The halting piece 24 extending from the hanger stopper2 c is inserted through a slit (not shown) of the cable stopper 42 tohalt the hanger stopper 2 c from further rotation driven by the hangerfixing bolt 4. A tool (not shown) is then implemented to drive thehanger fixing bolt 4 such that the fixing bolt 4 is fastened to thesecond axial bore 22 of the hanger stopper 2 c. The second axial bore 22of the hanger stopper 2 c may be formed with threads (not shown) thereinso as to facilitate the fastening operation. The fixing bolt 4 may alsobe fastened to the second axial bore 22 in a self-tapping manner so asto reduce manufacturing cost of the hanger stopper 2 c.

In the embodiment as shown in FIGS. 6 and 7, the fastening operationwill force the hanger stopper 2 c to move towards the C-shaped member36, subjecting the tapering lateral end 21 of the hanger stopper 2 c totuck into the axial bore 32 of the C-shaped member 36 and furthercausing the expanded C-shaped member 36 to slide towards the taperinglateral end 15 of the hose hanger 1 c, to secure the cable harnessassembly 100 c to the bicycle frame 40 due to expansion of the C-shapedmember 36.

In the embodiments as shown in FIGS. 6 and 7, the third diameter orwidth of the stopper bushing 3 c will expand in one way or another as aresult of the fastening operation of the hanger fixing bolt 4, so as toattain the desired mounting effect to the bicycle frame 40. Afterwards,a hose or hydraulic line 60 can be inserted into the cable portion 16 ofthe hose hanger 1 c by being pressed through the longitudinal opening162 to be secured to the bicycle frame 40, as shown in FIG. 9.

Another embodiment of this invention as shown in FIG. 8, discloses acable harness assembly 200 comprising a hose hanger 1 d, a stopperbushing 3 d and a hanger fixing bolt 4. The hose hanger 1 d,in thisembodiment, includes a body portion 12 of a first outer diameter orwidth, a cable portion 16 extending from the body portion 12, andopposite ends 15 and 17. The cable portion 16 of the hose hanger 1 d hasa C-shaped cross-section. The body portion 12 has a first outer diameteror width and is formed with a first axial bore 14 of a first innerdiameter or width therethrough. The body portion 12 of this embodimentis provided at one of the lateral ends 15 with a head 13 having a fourthouter diameter or width, preferably being smaller than the first outerdiameter or width of the body portion 12, having a lateral end 131. Asshown in FIG. 11, the hose hanger 1 d,in this embodiment, may beoptionally, a two-piece structure, where the head 13 is independent fromthe body portion 12. Alternatively, as shown in FIG. 8, the hose hanger1 d has a one-piece structure, where the head 13 is integrally formedwith the hose hanger 1 d. The hose hanger 1 d is integrally formed as aone-piece, unitary member by injection molding. In addition, FIG. 8shows that the head 13 extends from the end 15 such that the end 15forms an axially facing abutment surface that is at least locatedsubstantially radially opposite to the cable portion 16.

The stopper bushing 3 d is placed next to the hose hanger 1 d and formedwith a threaded axial bore 35 of a second inner diameter or widththerethrough. The stopper bushing 3 d is made of a rigid material, suchas metal or plastic, that has a third outer diameter or width beingapproximate to the fourth outer diameter or width of the head 13 of thehose hanger 1 d.

In this embodiment, the lateral end 131 of the head 13 of the hosehanger 1 d and the lateral end 37 of the stopper bushing 3 d next toeach other are both skewed, such that the fastening operation asdescribed previously, will force the stopper bushing 3 d to rotate andskew with respect to the head 13 of the hose hanger 1 d due the skewedinterface therebetween, to a point that interfacing tip of the head 13urges against the inner wall 44 of the cable stopper 42 so as to securethe cable harness 200 to the bicycle frame 40. The first inner diameteror width of the first axial bore 14 of the hose hanger 1 d may be,optionally, slightly bigger than the second inner diameter or width ofthe threaded axial bore 35 of the stopper bushing 3 d, to facilitate theskewing of the stopper bushing 3 d when the fixing bolt 4 is fastened tothe threaded axial bore 35 of the stopper bushing 3 d.

In this embodiment, the disposition between the stopper bushing 3 d andthe hose hanger 1 d changes as a result of the fastening operation ofthe hanger fixing bolt 4, to attain the desired mounting effect to thebicycle frame 40.

Apparently, the various embodiments of cable harness assembly 100 a, 100b, 100 c and 200 as described can be easily mounted to a conventionalcable stopper 42 without the necessity to dismantle the cable harnessassembly 100 a, 100 b, 100 c and 200 or involve extraneous work.

While only selected embodiments have been chosen to illustrate theinvention, it will be apparent to those skilled in the art from thisdisclosure that various changes and modifications can be made withoutdeparting from the scope of the invention as defined in the appendedclaims. Also, the foregoing description of the embodiments according tothe invention are provided for illustration only, and not for thepurpose of limiting the invention as defined by the appended claims andtheir equivalents.

What is claimed is:
 1. A cable harness assembly comprising: a hosehanger including a body portion and a cable portion extending from thebody portion, said hose hanger further including a neck portion joiningsaid body portion and said cable portion for enhancing flexibility ofsaid hose hanger, said cable portion being formed with a longitudinalslot having a central longitudinal axis, said body portion including afirst axial bore having a first inner width extending between oppositeends, said first axial bore extending along a first longitudinal axisthat is substantially parallel to said central longitudinal axis, saidbody portion being provided at one of said opposite ends with a headhaving a skewed end, said head extending from said one of said oppositeends such that said one of said opposite ends forms an axially facingabutment surface that is at least located substantially radiallyopposite said cable portion; a stopper bushing including a threadedaxial bore having a second inner width extending between opposite endsof said stopper bushing, said stopper bushing being located adjacentsaid hose hanger with one of said opposite ends of said stopper bushingbeing skewed and located adjacent said skewed end of said head of saidhose hanger; and a hanger fixing bolt extending through said first axialbore of said hose hanger and into said threaded axial bore of saidstopper bushing to couple said hose hanger and said stopper bushingtogether, said stopper bushing being rotated and further skewed withrespect to said head of said hose hanger when said hanger fixing bolt isthreaded into said threaded axial bore of said stopper bushing.
 2. Thecable harness assembly according to claim 1, wherein said first innerwidth of said first axial bore of said hose hanger is slightly biggerthan said second inner width of said threaded axial bore of said stopperbushing.
 3. The cable harness assembly according to claim 1, whereinsaid cable portion has a C-shaped cross-section.
 4. The cable harnessassembly according to claim 1, wherein said hose hanger is integrallyformed as a one-piece, unitary member by injection molding.
 5. The cableharness assembly according to claim 1, wherein said stopper bushing ismade of a rigid material.
 6. The cable harness assembly according toclaim 5, wherein said rigid material is plastic.
 7. The cable harnessassembly according to claim 5, wherein said rigid material is metal. 8.The cable harness assembly according to claim 1, wherein said hosehanger is a two-piece structure, with said head being independent fromsaid body portion.
 9. The cable harness assembly according to claim 1,wherein said hose hanger is a one-piece structure with said head beingintegrally formed with said hose hanger.
 10. A cable harness assemblycomprising: a hose hanger including a body portion and a cable portionextending from the body portion, said hose hanger further including aneck portion joining said body portion and said cable portion forenhancing flexibility of said hose hanger, said body portion including afirst axial bore having a first inner width extending along a firstlongitudinal axis between opposite ends, said cable portion including alongitudinal slot extending along a second central longitudinal axis andsaid second central longitudinal axis being substantially parallel tosaid first longitudinal axis, said body portion being provided at one ofsaid opposite ends with a head having a skewed end; a stopper bushingincluding a threaded axial bore having a second inner width extendingbetween opposite ends of said stopper bushing, said stopper bushingbeing located adjacent said hose hanger with one of said opposite endsof said stopper bushing being skewed and located adjacent said skewedend of said head of said hose hanger; and a hanger fixing bolt extendingthrough said first axial bore of said hose hanger and into said threadedaxial bore of said stopper bushing to couple said hose hanger and saidstopper bushing together, said stopper bushing being rotated and furtherskewed with respect to said head of said hose hanger when said hangerfixing bolt is threaded into said threaded axial bore of said stopperbushing.
 11. The cable harness assembly according to claim 10, whereinsaid first inner width of said first axial bore of said hose hanger isslightly bigger than said second inner width of said threaded axial boreof said stopper bushing.
 12. The cable harness assembly according toclaim 10, wherein said cable portion has a C-shaped cross-section. 13.The cable harness assembly according to claim 10, wherein said hosehanger is integrally formed as a one-piece, unitary member by injectionmolding.
 14. The cable harness assembly according to claim 10, whereinsaid stopper bushing is made of a rigid material.
 15. The cable harnessassembly according to claim 14, wherein said rigid material is plastic.16. The cable harness assembly according to claim 14, wherein said rigidmaterial is metal.
 17. The cable harness assembly according to claim 10,wherein said hose hanger is a two-piece structure, with said head beingindependent from said body portion.
 18. The cable harness assemblyaccording to claim 10, wherein said hose hanger is a one-piece structurewith said head being integrally formed with said hose hanger.